Bismaleimide-based solution for inkjet ink for three dimensional printing

ABSTRACT

A polyimidc-based solution for inkjet printing includes an α,ω-Bismaleimide(BMI) terminated oligomer, wherein said α,ω-Bismaleimide terminated oligomer is delined by formula (I), wherein R represents an aliphatic, an aromatic or mixed aliphatic and aromatic groups.

FIELD OF THE INVENTION

The present invention relates generally to polymeric ink composition for use in additive manufacturing (AM), and more particularly to development of polyimide (PI)-based solution, which may be used to form ink for three dimensional (3D) printing by inkjet technology.

BACKGROUND OF THE INVENTION

Additive manufacturing (AM) enables a new manufacturing paradigm, such as the rapid, distributive manufacture of complex objects. In order to expand 3D printing and make it more versatile, new processes are needed that are able to deposit a broader range of materials, including engineering polymers of different characteristics. Engineering polymers are materials with superior thermal stability and mechanical properties that make them valuable in the manufacture of structural products. Examples of engineering polymers include epoxy resins, polyurethanes, polyamides, polyacrylates, polycarbonates, polyesters and polyimides. Engineering polymers have better mechanical properties and/or thermal and chemical stability than the more widely used commodity plastics (such as acrylic materials, polystyrene, PVC, polypropylene and polyethylene).

In the case of POLYJET 3D printing technology, which is based on ink jet, the starting material is a curable formulation based on monomers and/or oligomers, curable mostly by heating or UV-VIS (ultraviolet visible) radiation. The POLYJET process requires strict ink characteristics enabling printing without orifice clogging (see e.g. Chin-Tai Chen (2011). Inkjet Printing of Microcomponents: Theory, Design, Characteristics and Applications, Features of Liquid Crystal Display Materials and Processes, Dr. Natalia Kamanina (Ed.), InTech, DOI: 10.5772/26225.):

-   -   The maximum allowed ink viscosity at jetting temperature is         10-150 mPa s (25-100° C.).     -   Ink surface tension 25-55 mN/m (depending on substrate).     -   High solid content of at least 20 wt. %.     -   Environmental friendliness.     -   Low boiling point solvents (<190° C.), but with low evaporation         rate at jetting temperature.     -   Hardening of the ink: UV curing and/or thermal curing, very fast         (less than 20 sec).     -   Max particles size, if unavoidable D100=1-2 micron.

Current inkjet technology offers the capability to use a range of polymeric materials with a variety of properties. Common printable polymers are mostly thermoplastic polymers such as, polypropylene, high-density (HD) polyethylene, acrylonitrile butadiene styrene (ABS), polyphenylsulfone (PPSU) or high impact polystyrene (HIPS). However, engineering polymers, especially PIs (polyimides) are not currently used as inks in inkjet AM. Though PI-based inks were proposed, their long curing time (10-60 min) does not enable their use in the POLYJET process (see US Patent Application 2011/0120753A1).

PIs as a class of materials are very promising due to a variety of desirable characteristics they possess, including high thermal stability, excellent mechanical properties, wear resistance, radiation resistance, inertness to solvents, low dielectric constants and good adhesion strengths. There are both thermosetting and thermoplastic PIs. Polyimide synthesis routes include both polycondensation and addition mechanisms. Aromatic PIs are generally prepared by a two-step procedure from aromatic diamines and aromatic tetracarboxylic dianhydrides.

The main obstacles in applying PIs in an inkjet 3D printing technology are: (i) slow curing kinetics accompanied by a release of a low-molecular weight products (water); (ii) very low solid content limiting the printing process; (iii) the use of high boiling point toxic solvents; (iv) the need for imidization and curing processes at elevated temperatures in the range of 150° C.-350° C.; (v) the need to remove high solvent content.

SUMMARY OF THE INVENTION

The present invention relates to a PI-based solution, which may be used to form ink for inkjet 2D and 3D printing. This solution consists of bismaleimide (BMI)—based chemical precursor dissolved in a suitable solvent (Route 1) or a stable suspension of BMI powder in an inert media (Route 2). Other additives may include radical polymerization initiators, photo-initiators, surfactants, stabilizers and reinforcement nano-particles. BMIs are a type of PIs that are used for preparation of thermosetting materials. They consist of imide moieties in low molecular weight pre-polymers that have reactive terminal or pendant groups, which undergo homopolymerization and/or copolymerization by UV, thermal or catalytic means resulting in a formation of cross-linked solid products. Such materials are characterized by relative ease of processing and the ability to tailor specific rheological properties by controlling the molecular weight. Additionally, crosslinked thermosetting PIs have excellent retention of physical properties at high temperatures, in wet environments and in the presence of solvents and lubricating fluids.

An ink substance may be mixed with the polyimide-based solution to form an ink.

The general structure of a BMI is shown here:

The double bond of the maleimide end-group is highly electron deficient due to the adjacent electron-withdrawing carbonyl groups. Hence, low molecular weight bismaleimide precursors can undergo homo- and/or copolymerization at the carbon-carbon double bond to provide a crosslinked network. Additionally, the unsaturated alkenyl group is a very reactive dienophile and, therefore, can undergo addition reactions such as Michael addition of amines and Diels-Adler addition of dienes.

DETAILED DESCRIPTION OF EMBODIMENTS

In one embodiment, the solution development is based on a solution of reactive BMI oligomers dissolved in organic solvent (Route 1).

The solution contains α,ω-Bismaleimide terminated oligomers with or without reactive additives.

The α,ω-Bismaleimide compound is defined by a general formula (1):

wherein R represents an aliphatic, aromatic or a mixed aliphatic and aromatic groups.

The reactive BMI containing oligomers include liquid or powder BMI resins and/or imide-extended BMI oligomers with the average molecular weight up to 10,000, preferably from 500 to 3000 Daltons.

The reactive additives include oligomeric polyamines that undergo Michael addition reaction with α,ω-Bismaleimide terminated oligomers.

Suitable organic solvents are characterized by a boiling temperature below 190° C. and low evaporation rate, lower than 1 (preferably lower than 0.3).

The suitable solvents include alcohols, or esters of carboxylic acids defined by a general formula (2):

wherein R and R′ represent different alkyl groups, which are not related to those mentioned in formula (1).

The oligomeric BMI component undergoes quick curing (1-20 seconds per layer), forming a three-dimensional network of a thermosetting polymer material.

The curing can be done by a thermal treatment, UV irradiation, or both.

Photo-curing can be done by UV sources, such as Xe lamp, mercury lamp, LED UV lamp, intense pulsed light (IPL), or UV laser, with intensity of up to 2000 J/cm² in the UV-VIS spectral range.

For enhancement of UV curing, photo-initiators can be added at 0.1-5 wt. %. The examples of photo-initiators are a-hydroxyketones, Bis(2,4,6-trimethylbenzoyl)-phenylphosphineoxide, or their combination.

Thermal curing can be done by UV-VIS radiation or conduction, for example by using IR lamp, and/or heating of the printed surface by heating of the printing tray or the environment in the chamber.

Thermal curing can be enhanced by addition of peroxide catalyst, such as dicumyl peroxide (added at 0.01-2 wt. %) or epoxy catalyst.

EXAMPLE

BMI-based solutions were prepared by mixing BMI precursor in different solvents, such as butyl acetate, hexyl acetate, or ethyl caproate from Sigma Aldrich. Imide-extended or linear-chain extended BMI oligomers, such as BMI1400, BMI1500, BMI1700, BMI3000, or BMI689 from Design Molecules Inc. were used as Bismaleimide precursors. The homogeneous nature of the solutions was assisted by a vortex mixer, Velp. Scientifica, ZX classic at 3000 rpm for 1 min, and a sonicator, Kudus, SK221OHP at 53 kHz and 40° C. for 30 min. Solubility of the Irgacure 819 photoinitiator from BASF Dispersions & Pigments was achieved by heating the BMI-based solution in an oven up to 85° C. The viscosity of BMI-based solutions was measured by a viscometer (DV-I Prime, Brookfield) with thermoregulation by water circulation (Ministat 125, Huber). The examples of achieved viscosities at various tempeartures are shown in Table 1.

TABLE 1 Viscosities of the BMI-based solutions Temperature Viscosity Solution composition (° C.) (mPa · s) BMI3000 (30 wt. %) in n-Buthyl Acetate 40 11 50 9 60 7 BMI3000 (40 wt. %) in n-Buthyl Acetate 40 29 50 19 60 16 BMI3000 (40 wt. %) in Hexyl Acetate 40 88 60 21 65 14 BMI689 (60 wt. %) in Hexyl Acetate 40 15 60 9 65 7 BMI689 (80 wt. %) in Hexyl Acetate 40 65 60 24 65 19 The invention is not limited to these examples. 

1-13. (canceled)
 14. A curable liquid composition for inkjet 3D printing comprising: (A) The Bismaleimide (BMI) α,{acute over (ω)}-terminated compound defined by the general formula (1):

where “—R—” is a bivalent spacer that include hydrocarbon group like the alkylene-, alkylidene-, arylene-, aralkylene-, alkarylene-groups, and groups, containing heteroatoms such as Si, O, S, N and P. (B) Organic diluent or solvent (C) Reactive additives.
 15. The composition according to claim 14, wherein said α,{acute over (ω)}-BMI-compounds (A) are used as a low viscous solution in a suitable Organic solvent (B) in combination with Reactive additives (C).
 16. The composition according to claim 14, wherein said reactive additives (C) consist in curing initiators, reagents and surfactants.
 17. The composition according to claim 14, wherein said α,{acute over (ω)}-BMI-compounds (A) undergoes quick thermal- and (or) photo-initiating curing during inkjet 3D printing process (1-20 sec. per layer) in the presence of the Reactive additives (C).
 18. The composition according to claim 16, wherein said α,{acute over (ω)}-BMI-compounds (A) are used in combination with oligomeric polyamine (C), containing reactive N—H bonds, that undergoes Michael addition reaction to said BMI-compounds during the thermal curing process.
 19. The composition according to claim 16, wherein said α,{acute over (ω)}-BMI-compounds (A) are used in combination with allyl- or vinyl-containing hydrocarbons like 1,4-Dihydro-1,4-methanonaphthalene, 1-Vinylnaphthalene or 2,2′-Diallyl-bisphenol A diacetate ether added at 0.5-5 wt. % (C).
 20. The composition according to claim 16, wherein said α,{acute over (ω)}-BMI-compounds (A) are used in combination with free radical initiators such as Dicumyl peroxide and 2,2′-Azobis(2-methylpropionitrile) (added at 0.01-0.2 wt. %) for the thermal curing process initiation (C).
 21. The composition according to claim 16, wherein said α,{acute over (ω)}-BMI-compounds (A) are used in combination with photo-initiator added at 0.1-5 wt. % (C).
 22. The composition according to claim 16, wherein photo-initiator (C) comprises an α-Hydroxyketone, Bis(2,4,6-trimethylbenzoyl)-phenylphosphinoxide, or a combination thereof.
 23. The composition according to claim 14, wherein said solvents (B) characterized by a boiling temperature below 190° C. and an evaporation rate lower than
 1. 24. The composition according to claim 14, wherein said solvents (B) comprises Alcohols, Mono-alkyl ethers like 2-Ethoxyethanol or 2-Butoxyethanol and Alkyl carboxylates like n-Alkyl Acetates and n-Alkyl Propionate with Alkyl=C_(n)H_(2n+1), n=4-8.
 25. The composition according to claim 14, wherein said α,{acute over (ω)}-BMI-compounds (A) are used as a stable solutions with the concentration of curable compounds 25-90 wt. %.
 26. The composition according to claim 14, wherein said BMI-based solutions have viscosities 7-90 mPa·s at 40-70° C.
 27. The composition according to claim 14, wherein said α,{acute over (ω)}-BMI-compounds (A) are used as a stable suspension of a micronized powders in an inert organic diluent (B) in combination with Reactive additives and surfactants (C).
 28. The composition according to claim 27, wherein said α,{acute over (ω)}-BMI-compounds (A) are used as a stable suspension of a micronized powders in an inert organic diluent (B) in the presence of suitable nonionic surfactant (C) of the Alkyl Polyglucoside type or Lauryl Dimethyl amine oxide.
 29. The composition according to claim 27, wherein said nonionic surfactant is added at 0.005-0.1 wt. % during micronization of the BMI-compounds (A) with the melting point higher than 20° C. .
 30. The composition according to claim 14, wherein said α,{acute over (ω)}-BMI-compounds (A) have the molecular weight from 250 to 10,000 Dalton, preferably 500-1500 Dalton and can be represented both as individual compounds, and as α,{acute over (ω)}-Bismaleimide-terminated oligomers.
 31. The composition according to claim 14, wherein said α,{acute over (ω)}-BMI-compound (A) has the molecular weight 689 Dalton and can be used alone or in the mixture with another BMI-compounds. 